Suspended ceiling system

ABSTRACT

A suspended ceiling system having a repetitive modular appearance includes unique, removable, collapsible frame portions in which either finished panels or lighting fixtures can be centrally positioned away from the lower plane of the modules to form upwardly recessed coves.

United States. Patent White et al. 1 1 June 13, 1972 [54] SUSPENDEDCEILING SYSTEM 3,343,310 9/1967 [72] Inventors: Richard N. White, DesPlaines, 111.; Joseph 2044588 6/1936 D. Wilkin Tampa Fla 3265879 8/19663,062,954 11/1962 [73] Assignee: The Celotex Corporation, Tampa, Fla.3,512,313 5/1970 FebI 3 426, 1 Baranowski X PP'- 9,885 PrimaryEraminer-Frank L. Abbott Assistant Examiner-Henry E. Raduazo [52] US. Cl..52/28, 52/646, 52/144, Grace 52/484, 52/DIG. 8 [51] Int. Cl ..E04b5/52 ABSTRACT [58] Field Search A suspended ceiling system having arepetitive modular apl l pearance includes unique, removable,collapsible frame portions in which either finished panels or lightingfixtures can be [56] References Cited centrally positioned away from thelower plane of the modules UNITED STATES PATENTS to form upwardlyrecessed coves.

603,474 5/1898 Sebold ..108/131 9 Claims, 9 Drawing Figures PATENTEnJun13 1912 SHEET 10F 3 I\\\\-ES\IIHIIEI/IMW INVENTORS RICHARD N.WHITEJOSEPH D. WILKIN ATTORNEY.

PATENTEDJuu 13 m2 3. 668.826 sum 2 or 3 4O F|G.3 5'

. IZNVENTORS RICHARWNWHITE SEPH D.WILK|N ATTORNEY.

PATENTEUJUH 13 1912 SHEET 3 [IF 3 ATTORNEY.

SUSPENDED CEILING SYSTEM BACKGROUND or THE INVENTION The ceiling systemcomprises a grid which forms a series of rectangular openings in theplane of the ceiling at least some of the openings being filled with astructure which forms a series of modular, upwardly recessed coves orhollow truncated pyramids. The sides of the recessed coves are formed ofsound absorbing panels while the upper rectangular openings containlight fixtures or sound absorbing panels.

2. Description of the Prior Art Until rather recently suspended ceilingsystems have generally comprised a metal grid network which is suspendedfrom an overhead building structure, usually the underside of the floorabove the ceiling, and acoustical panels disposed in the general planeof the grid. If desired, certain of the acoustical panels may bereplaced with lighting fixtures to provide illumination for the roombelow the ceiling.

The current fashion for ceilings has resulted in a ceiling designed on amodular basis with recessed areas in the form of coves or truncatedpyramids rising above the plan of the grid system. In some designs arectangular, modular grid system forms a base for splines extendingupwardly to terminate in a smaller rectangular frame. Acoustical panelsare supported on these splines and fill the area between the two levelsof the system to form the sides of the hollow, truncated pyramid. Theupper plane of the recess may contain an acoustical panel or a lightfixture, as desired. For variation, only certain ones of the recessesmay be closed with light fixtures and others with acoustical panels.Thus, a ceiling suspension system is provided which can lend itself todesign flexibility.

The current ceiling systems, however, are costly to erect and require asignificant amount of time to assemble the various components on thejobsite. In one such type the light fixture is held in place by spacedinverted U-shaped brackets which must be bolted both to the fixture andto the supporting grid. With this system splines are used to support theacoustical panels along contiguous edges.

Packaging and shipping of the modular units presents problems inrequiring large packages and numerous individual components.

At times costly jurisdictional disputes arise between the variousbuilding trades, such as sheet metal works, carpenters and electrictiansas a result of unclear distinctions in the method of assembly of theceilings. When the light fixtures can be dropped into a frame withoutfurther assembly, the jurisdictional disputes involving the electricalworkers are minimized.

SUMMARY OF THE INVENTION The present invention is directed to a novelmodular ceiling system in which a collapsible, removable frame forms asupporting structure for a truncated pyramidal assembly. The assemblymay incorporate decorative or acoustical panels as well as lightfixtures. Design flexibility is provided in that a wide variety ofceiling styles can be installed.

It is, therefore, an object of the present invention to provide a novelsuspended ceiling system which is easily assembled with a minimum oflabor.

It is another object of the present invention to provide a novelsuspended ceiling system which pennits easy rearrangement andflexibility in design.

It is yet another object of the present invention to provide a novelsuspended ceiling system which can be easily packed in an efficientmanner with a minimum of parts.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of theinvention will become apparent when the detailed description isconsidered in conjunction with the accompanying drawings in which likeelements are referred to by like numbers and in which FIG. 1 is aperspective view of a portion of a suspended ceiling system of theinvention;

FIG. 2 is an expanded elevational view of a portion of the ceiling ofFIG. I, viewed from above, with certain elements removed;

FIG. 3 is a cross-sectional view of a portion of the suspended ceilingof FIG. 2 taken along lines 3-3 thereof with an upper portion cut away;

FIG. 4 is a cross-sectional view of a portion of the ceiling of FIG. 2taken along lines 4-4 thereof;

FIGS. 5 and 6 are detailed views of pertinent segments of top and bottomportions of the ceiling system of FIG. 4 taken along lines 5-5 and 6-6respectively thereof;

FIG. 7 is a detailed view of an alternative suspension grid system ofthe ceiling system, and

FIGS. 8 and 9 are alternative elevational views of the frame portion ofthe ceiling of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. I of thedrawings, there is shown an embodiment of the ceiling system of theinvention, as viewed in perspective from below. In general, the ceilingsystem comprises a basic grid network 10 and cove-forming structure 11supported by the grid network 10. Grid network 10 comprises mainsuspension grid members 12 in spaced parallel rows in the lower plane ofthe ceiling, and cross-suspension members 14 interconnected to andspanning main suspension grid members 12. For convenience, the spacingbetween members 12 is 60 inches on centers. Cross-members 14 are spacedin parallel rows on 60-inch centers and connected to the main suspensionmembers 12. Thus, a basic modular effect is achieved with the modulesbeing 60 inches on each side. If desired, modules of other dimensionsmay be selected.

To support the ceiling suspension system, wires 15 are connected fromthe main suspension members to an overhead supporting structure 17 whichis usually the underside of the floor above the room containing theceiling. In practice, the suspension grid system is installed andaligned in a predetermined horizontal plane by adjusting the lengths ofwires 15.

The cove-forming structure 11 (shown in greater detail in FIG. 2)comprises a main rectangular frame 19 having four sides 21, 22, 23 and24. Sides 21-24 are connected by bolts or welding or the like at theirrespective abutting ends to form a rigid frame. Legs 27, 28, 29 and 30are pivotally attached to and depend from respective corners of frame 19to hold the frame 19 in a plane away from and above the face plane ofthe main suspension system 10. Legs 27 30 are of equal length and may becut from a long piece of right-angle channel iron or aluminum. As willbe discussed in greater detail hereafter, legs 27 30 are pivotallymounted at their upper ends and also arranged to lock into place attheir upper and lower ends so as to provide a strong support for thepanels and light fixtures of the ceiling.

Side panels (shown in FIGS. 3 and 4), which may be decorative andacoustically absorbent, are removably supported at their top edges bysides 21 24, their side edges by legs 27 30 and their bottom edges bysuspension members 12 and 14. As can be appreciated, the panels 35 mayall be trapezoidal in shape, or for each modular opening or cove twopanels may be trapezoidal and the other two can be rectangular. However,the appearance shown by each panel as viewed from below will betrapezoidal.

Frame 19 is arranged to support a light fixture (shown in partialoutline in FIGS. 3 and 4). If desired, light fixture 40 may be replacedby an acoustical or decorative panel depending upon the preference andwishes of the designer. The removable frame 19 is, thus, capable ofproviding a wide variety of design options.

Typical of the sides of frame 19 is side 21 (shown in greater detail inFIG. 3). Side 21 has a horizontal flange extending inwardly from avertical web 51. Vertical web 51 has a double thickness with an integraldownwardly and outwardly extending flange 53. Side 21 can be made byroll-forming a single wide sheet of steel or by welding two separatelyformed pieces together. A pivot hole is drilled into flange 53 at oneend of side 21 to receive a rivet 56 or other pivot-providing connectorfor the upper end of leg 27. Because all four legs 21 24 are of similarconstruction it can be easily seen that frame 19 forms a horizontal bedwith an inwardly facing rim formed by the horizontal flanges of thesides. The horizontal bed is surrounded by a vertical wall formed aroundthe periphery of the bed by the vertical webs 51 of sides 21 24, Inaddition, an outwardly and downwardly flaring skirt is provided aroundframe 19 by the flanges 53 around the outside of the vertical webs ofthe sides 21 24.

The symmetry of the construction of frame 19 can be further realized bya consideration of FIG. 4 which is a view taken at right angles to FIG.3. In FIG. 4, the flanges and web side 22 are referenced by likenumbers, as in FIG. 3, but with a small a" added as a suffix.

In order to lock the upper end of leg 27 (and in similar manner all ofthe legs 27 30 of frame 19) against pivoted rotation beyond a desiredamount, a small piece 60 of the outwardly flaring flange 53a adjacentthe pivotal flange is punched inwardly to form a finger which receives aportion of the upper end 61 of leg 27.

FIG. shows a detailed view of the locking feature of the invention. End61 of leg 27 engages piece 60 of the flange 53a.

It is thus seen that the upper area of the cove is formed by the upperpivoted ends of legs 27- 30 engaging flaring skirts of frame 19. Frame19 presents a bed to receive a light fixture or panel as desired.

Legs 21 24 extend outwardly and downwardly to span the area betweenframe 19 and grid network and to support frame 19 in interlockingrelation therewith.

FIGS. 3 and 6 illustrate the structural details of the interengagementof the suspension members 12 and 14 with the lower end of leg 27. Leg 27is made of a piece of sheet metal with two sides at an angle withrespect to each other. The lower end of leg 27 is bifurcated with twoextending portions 68 and 69. The tip ends 70 and 71 of leg 27 have bentflange portions which are designed to fit snugly against web portions 72of suspension member 14; while tip end 71 of side 66 engages the insideweb portion 73 of suspension member 12.

While the tips 70 and 71 are shown in FIGS. 4 and 6 as being bentdownwardly, if the angle of approach of leg 27 toward the grid membersis steep enough as shown in FIG. 3, the tip ends 70 and 71 will behorizontal and rest upon the lower horizontal portion 75 of thesuspension members.

The steepness of the angle made between the legs and the suspensionmembers is determined by the relative size of frame 19 and the size ofthe module opening. In any event it can be seen that the weight of frame19 causes a wedging action between the lower ends of the legs 27 30 andthe suspension members 12 and 14. Because the lower ends of the legs arebifurcated, the legs engage the inner sides 72 and 73 of twoperpendicularly related suspension members and are locked againstrotation, giving rigidity to the entire assembly without requiring weldsor bolts.

As can be seen from FIGS. 3 and 4, the cross-sectional configuration ofsuspension members 12 and 14 are similar and may be described asconsisting of three parallel U-shaped sections 76, 77 and 78 with thecentral U-shaped portion 77 being raised with respect to the twooutwardly flanking U-shaped sections 76 and 78. The suspension memberscan be made of a single sheet of metal formed by rolling into thedesired shape. Obviously the cross-section of the suspension members canbe varied and could be as simple as an inverted T-shaped one. Referencemay be had to FIG. 7 as an illustration of this latter modification.Here two outwardly extending flanges 80 and 81 are integrally connectedto a central upstanding web portion 83. The lower tip ends 70 of leg 27engages the flange 80. Correspondingly the lower tip end 71 of leg 27engages the other cross-member (not shown).

To illustrate the versatility of the cove-forming structure of theinvention reference may be had to FIG. 8 which shows the frame 19 andthe legs 27 30 in retracted position for shipping. The legs 27 30 arealso shown in phantom lines, as if extended. When arranged for shippingthe legs 27 30 are rotated around their pivotal rivets 56 and nestagainst their respective sides 21 24 of frame 19. As alternativestructures, the legs 27 30 may lie above or below the flanges 53 ofsides 21 24. Furthermore, the legs 27 30 may be pivoted so that two legsmay nest against the same side of the frame 19.

FIG. 9 shows a frame 19 which is of square configuration, rather thanbeing merely rectangular in shape.

In summary, the present invention is directed toward a novel ceilingsuspension system is versatile and flexible in use and packaging andwhich comprises a minimum of components for easy assembly.

We claim:

1. A ceiling suspension system comprising:

A rectangular structural member having four comers; and further havingan outwardly and downwardly flaring skirt forming a lower peripheralextension of said structural member; a plurality of legs of V-shapedcross-section, each leg having one end pivotally attached at acorresponding comer of said skirt so that each of the said legs can bemoved from a nesting position with respect to said structural member toan outwardly and downwardly extending position;

a grid system having suspension members connected together and arrangedto form a repeatable modular configuration;

said suspension members having coplanar horizontal flanges and verticalweb portions integral with and spaced from the free edges of saidhorizontal flanges, said horizontal flanges and vertical web portion ofone of said suspension members meeting with a horizontal flange andvertical web portion of an adjacent suspension member at a right anglemeans on said skirt to limit pivotal movement of each of said legs, and

means on each of said legs remote from said pivotally attached endsengaging corresponding ones of said horizontal flanges and said verticalweb portions of said abutting suspension members.

2. A ceiling suspension system as recited in claim 1 in which saidrectangular structural member comprises four sides, each of said sideshaving a vertical flange forming an outer edge for the reception of aceiling enclosing member;

a horizontal flange integral with said vertical flange extendinginwardly from said vertical flange for supporting a ceiling enclosingmember,

and an outwardly and downwardly extending skirt connected to saidvertical flange for connection to said legs.

3. A ceiling suspension system as recited in claim 2 in which each ofsaid outwardly and downwardly extending skirts has a pivot meanssecuring said legs to each of said outwardly and downwardly extendingskirts.

4. A ceiling suspension system as recited in claim 1 in which each endof each of said legs remote from said structural member has a V-shapedcut-out portion to form a bifurcated end and each bifurcated end hasbent flange portions interlockingly engageable with said grid suspensionmembers.

5. A ceiling suspension system as recited in claim 2 in which ceilingcompleting units are mounted on said structural member.

6. A ceiling suspension system as recited in claim 5 in which at leastone of said ceiling completing units is a light fixture.

7. A rectangular structural member and leg assembly having four cornersfor supporting ceiling panels in a suspended ceiling system to form amodular ceiling of adjacent hollow truncated pyramids, and furtherhaving an outwardly and downwardly flaring skirt forming a lowerperipheral extension of said structural member; adjacent sides of saidskirt forming an inverted V-angle; a plurality of legs of V-shapedcross-section complementary to said V-angle; each leg having one endpivotally attached at a corresponding corner of said skirt, each of saidlegs being folded in nesting relationship with a cor- 8. A rectangularstructured member and leg assembly as responding side of said skirt andbeing adapted to being exrecited in claim 7 in which said frame has foursides tended outwardly and downwardly in divergent relationship h f aidside having a vertical flange forming an outer with respect to saidstructural member and to each other when edge f the fecepion f f el in bin their extended positions, each leg having a cut-out section 5 ahorizontal flange integral with said vertical flange extend in its endremote from said pivotally attached end, said remote ing inwardly fromSaid vertical flange for supporting said end being adapted to engage agrid structure, and locking frame closing member means punched out ofeach side of said skirt spaced from said and an outwardly extendingflange connected to Said verti pivotally attached ends of each of saidlegs for limiting the excarflange for pivotal connection ofsaid legs.

tent of pivoted motion of each of sa d legs whereby the legs 10 9 Arectangular Strucmr a1 member and leg assembly as can be moved from anesting position with respect to said recited in claim 7 m which each ofsaid outwardly and structural member to and locked in an outwardly and dd] dbl l h v h d t t ff downwardly extending relationship with respectto said strucownwa? yexten l e egs asa cu Po 0 form a bifurcated endremote from said pivoted end.

tural member and to each other when in their extended positions.

1. A ceiling suspension system comprising: A rectangular structuralmember having four corners; and further having an outwardly anddownwardly flaring skirt forming a lower peripheral extension of saidstructural member; a plurality of legs of V-shaped cross-section, eachleg having one end pivotally attached at a corresponding corner of saidskirt so that each of the said legs can be moved from a nesting positionwith respect to said structural member to an outwardly and downwardlyextending position; a grid system having suspension members connectedtogether and arranged to form a repeatable modular configuration; saidsuspension members having coplanar horizontal flanges and vertical webportions integral with and spaced from the free edges of said horizontalflanges, said horizontal flanges and vertical web portion of one of saidsuspension members meeting with a horizontal flange and vertical webportion of an adjacent suspension member at a right angle means on saidskirt to limit pivotal movement of each of said legs, and means on eachof said legs remote from said pivotally attached ends engagingcorresponding ones of said horizontal flanges and said vertical webportions of said abutting suspension members.
 2. A ceiling suspensionsystem as recited in claim 1 in which said rectangular structural membercomprises four sides, each of said sides having a vertical flangeforming an outer edge for the reception of a ceiling enclosing member; ahorizontal flange integral with said vertical flange extending inwardlyfrom said vertical flange for supporting a ceiling enclosing member, andan outwardly and downwardly extending skirt connected to said verticalflange for connection to said legs.
 3. A ceiling suspension system asrecited in claim 2 in Which each of said outwardly and downwardlyextending skirts has a pivot means securing said legs to each of saidoutwardly and downwardly extending skirts.
 4. A ceiling suspensionsystem as recited in claim 1 in which each end of each of said legsremote from said structural member has a V-shaped cut-out portion toform a bifurcated end and each bifurcated end has bent flange portionsinterlockingly engageable with said grid suspension members.
 5. Aceiling suspension system as recited in claim 2 in which ceilingcompleting units are mounted on said structural member.
 6. A ceilingsuspension system as recited in claim 5 in which at least one of saidceiling completing units is a light fixture.
 7. A rectangular structuralmember and leg assembly having four corners for supporting ceilingpanels in a suspended ceiling system to form a modular ceiling ofadjacent hollow truncated pyramids, and further having an outwardly anddownwardly flaring skirt forming a lower peripheral extension of saidstructural member; adjacent sides of said skirt forming an invertedV-angle; a plurality of legs of V-shaped cross-section complementary tosaid V-angle; each leg having one end pivotally attached at acorresponding corner of said skirt, each of said legs being folded innesting relationship with a corresponding side of said skirt and beingadapted to being extended outwardly and downwardly in divergentrelationship with respect to said structural member and to each otherwhen in their extended positions, each leg having a cut-out section inits end remote from said pivotally attached end, said remote end beingadapted to engage a grid structure, and locking means punched out ofeach side of said skirt spaced from said pivotally attached ends of eachof said legs for limiting the extent of pivoted motion of each of saidlegs; whereby the legs can be moved from a nesting position with respectto said structural member to and locked in an outwardly and downwardlyextending relationship with respect to said structural member and toeach other when in their extended positions.
 8. A rectangular structuredmember and leg assembly as recited in claim 7 in which said frame hasfour sides each of said sides having a vertical flange forming an outeredge for the reception of a frame-closing member, a horizontal flangeintegral with said vertical flange extending inwardly from said verticalflange for supporting said frame-closing member, and an outwardlyextending flange connected to said vertical flange for pivotalconnection of said legs.
 9. A rectangular structural member and legassembly as recited in claim 7 in which each of said outwardly anddownwardly extendible legs has a V-shaped cut-out portion to form abifurcated end remote from said pivoted end.